Tire Vulcanization Steam Condensation Vacuum Generation
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Solution Overview
Problem
Current vehicle tire manufacturing methods require energy-intensive vacuum pumps and complex systems for evacuating steam condensate, leading to high energy costs, long emptying times, and significant maintenance needs.
Innovation Solution
The method employs steam condensation to generate vacuum, eliminating the need for a separate vacuum pump and using a single flow line for both filling and emptying, integrated with a cyclone, condenser, and heat exchanger for efficient steam management and heat recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum pumps are used to evacuate the molded body, then the gas residue is removed effectively, but energy consumption increases and emptying time becomes excessively long
Solution Approach 1:
The patent replaces the mechanical vacuum pump system with a thermal condensation system. Instead of using mechanical means (vacuum pumps) to remove gas, the invention uses thermal means (condensing steam) to create vacuum and remove condensate, thereby eliminating the energy-intensive mechanical vacuum pumping step while maintaining effective gas residue removal.
Solution Approach 2:
The patent utilizes the phase transition of steam from gas to liquid (condensation) to generate vacuum. By condensing the steam introduced during vulcanization, the volume of the steam decreases dramatically, creating a vacuum effect that automatically evacuates the molded body without requiring external vacuum pumps, thus reducing energy consumption and emptying time.
2Reliability
If liquid ring vacuum pumps are used to generate vacuum, then the required vacuum level is achieved, but acquisition costs and maintenance costs increase
Solution Approach 1:
The patent implements a self-service system where the steam condensation process itself generates the vacuum needed for evacuation. The system uses its own steam (introduced during vulcanization) and converts it into a vacuum-generating force through condensation, eliminating the need for separate vacuum generation equipment and reducing both investment and maintenance costs.
Solution Approach 2:
The patent extracts the vacuum generation function from the complex liquid ring vacuum pump system and integrates it into the steam condensation process. By removing the need for separate vacuum pumps and their associated infrastructure (cooling systems, storage tanks), the invention significantly reduces acquisition costs and maintenance requirements while maintaining the necessary vacuum level.
3Reliability
If vacuum pumps and storage tanks are used, then vacuum is generated and stored, but cooling energy is required and device complexity increases
Solution Approach 1:
The patent merges the vacuum generation function with the steam condensation process. Instead of having separate systems for steam handling and vacuum generation, the invention combines these functions so that the condensation of steam directly creates the vacuum needed for evacuation, simplifying the overall system architecture and eliminating the need for separate vacuum pumps, storage tanks, and cooling systems.
Solution Approach 2:
The patent makes the steam condensation system multi-functional: it serves both as the heat treatment medium during vulcanization and as the vacuum generation mechanism for evacuation. This universal approach eliminates the need for dedicated vacuum equipment and reduces system complexity while maintaining reliable vacuum generation.
4Reliability
If two separate pipelines are used for evacuation and vacuum, then the emptying process is complete, but the system complexity and emptying time increase
Solution Approach 1:
The patent merges the evacuation and vacuum functions into a single pipeline system. By using one pipeline for both steam introduction and condensate evacuation, the system eliminates the complexity of coordinating two separate pipelines while maintaining complete emptying through the vacuum generated by steam condensation, thereby improving emptying speed and productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production time, energy consumption, and maintenance effort, enabling faster tire production with lower costs and simpler equipment, while effectively managing steam condensate and non-condensable gases.
Implementation Method 1
for the generation of the vacuum, steam condensation is used with a reduction in the temperature of the steam
Implementation Method 2
steam condensation is used with a reduction in the temperature of the steam
Implementation Method 3
a cyclone or moisture separator
Implementation Method 4
a condenser and a heat exchanger
Data Source
Figure 1
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AI summary
A method for manufacturing a vehicle tire (1) using a vulcanization tool (2) is presented, wherein, during vulcanization, to form the inner cavity of the vehicle tire (1) which can be filled with air after completion, an elastically deformable mold (3) inserted into the vehicle tire blank is filled with a pressurized gas. After vulcanization is complete, the gas is first drained from the mold (3) until the pressure level in the mold (3) corresponds to normal atmospheric pressure. In a subsequent draining step, any remaining gas is completely extracted from the mold (3) by means of a vacuum. According to the invention, vapor condensation with a reduction in the vapor temperature is used to generate the vacuum. Furthermore, the invention relates to a manufacturing unit for applying the method.